Booklet feeder systems and methods

ABSTRACT

The present subject matter relates to systems and methods for advancing booklets from a group of booklets are provided. In particular, a booklet feeder can include a conveying path for supporting a group of booklets with each booklet comprising a stack of bound sheet articles, and a grip remover configured for engaging booklets in a seriatim manner in the conveying path. The grip remover can be movable to remove an engaged booklet from the conveying path and advance the removed booklet to an exit path.

TECHNICAL FIELD

The subject matter disclosed herein relates generally to systems andmethods for document handling and processing technologies. Moreparticularly, the subject matter disclosed herein relates to bookletfeeder systems and methods for processing or advancing booklets that canbe of varying thicknesses.

BACKGROUND

Machines for feeding documents seriatim from a stack can be useful in awide variety of document processing applications, such as printing,separating, collating, folding, scoring, and inserting machines, to namea few. A number of options are available for feeding documents in thismanner, including friction rollers, reciprocating friction pusherfeeders, grippers, and clamps-type devices, and including top-feeding orbottom-feeding systems. When booklets of multiple pages are to beadvanced or fed, however, the thicknesses of the booklets can limit theoptions available.

In particular, currently-used systems for feeding booklets, such asfriction feeders, generally require all of the booklets to be fed tohave the same booklet thicknesses (i.e., the same page count and pagethicknesses). If the booklets are too thick, they may not fit throughthe feeder assembly. If the booklets are too thin, they may not be takenup by the feeder assembly. As a result, the required uniformity preventsmany choices of customization in the variety of booklets that can beprocessed in the same stack. Accordingly, current booklet feeders areill-suited to provide a wide range of options for document processing.

SUMMARY

In accordance with this disclosure, systems and methods for advancingbooklets from a group of booklets are provided. In one aspect, a bookletfeeder is provided having a conveying path for supporting a group ofbooklets with each booklet comprising a stack of bound sheet articles,and a grip remover is provided and configured for engaging booklets in aseriatim manner in the conveying path. The grip remover can be movableto remove an engaged booklet from the conveying path and advance theremoved booklet to an exit path.

In another aspect, the booklet feeder can be provided with a conveyingpath for supporting a group of booklets having non-uniform bookletthicknesses, at least one vacuum picker assembly configured for engagingbooklets in a seriatim manner in the conveying path, and a controllerconnected to the at least one vacuum picker assembly for controlling themovement of an engaged booklet from the conveying path to the exit path.The conveying path can itself comprise a supply conveyor for advancingthe group toward an end of the conveying path. The at least one vacuumpicker assembly can be movable to remove an engaged booklet from theconveying path and advance the removed booklet to an exit path.

In yet other aspects, methods for advancing booklets from a group ofbooklets are provided. The methods can include supporting one or morebooklets in a conveying path, engaging one of the booklets in theconveying path using a grip remover, removing the engaged booklet fromthe conveying path, and advancing the removed booklet to an exit path.

Some of the aspects of the subject matter disclosed herein having beenstated hereinabove, and which are achieved in whole or in part by thepresently disclosed subject matter, other aspects will become evident asthe description proceeds when taken in connection with the accompanyingdrawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present subject matter will be morereadily understood from the following detailed description which shouldbe read in conjunction with the accompanying drawings that are givenmerely by way of explanatory and non-limiting example, and in which:

FIG. 1 is a perspective view of a booklet feeder according to an aspectof the presently disclosed subject matter;

FIG. 2 is a perspective view of a booklet feeder according to an aspectof the presently disclosed subject matter with the interior componentsexposed;

FIG. 3 is an elevated side view of an interior of a booklet feederaccording to an aspect of the presently disclosed subject matter; and

FIGS. 4 through 7 are side views of an interior of a booklet feeder insequential steps of operation according to an aspect of the presentlydisclosed subject matter.

DETAILED DESCRIPTION

Reference will now be made in detail to presently preferred aspects ofthe present subject matter, one or more examples of which are shown inthe figures. Each example is provided to explain the subject matter andnot as a limitation. In fact, features illustrated or described as partof one embodiment can be used in another embodiment to yield still yetanother embodiment. It is intended that the present subject mattercovers such modifications and variations.

The present subject matter provides systems and methods for advancingbooklets from a group of booklets. As will be appreciated by those ofskill in the art, references to a “booklet” can be understood to mean,as an example and without limitation, a stack of bound sheet articles orthe like. Further, the term “bound” should be understood to mean, as anexample and without limitation, anything that suitably holds ormaintains a stacked group of sheet articles together. In particular,such systems and methods can be used in document processing systems suchas, for example, mail inserting systems, mail sorting systems, and anyother suitable sheet processing systems. In one aspect, the presentsubject matter provides a booklet feeder, generally designated 100, foradvancing booklets such as booklet 130 from a group of booklets. Bookletfeeder 100 can include a conveying path, generally designated 120, forsupporting a group of booklets (only a single booklet 130 is illustratedin FIG. 1 to show the underlying features of conveying path 120). Forinstance, conveying path 120 can comprise a supply conveyor 115 foradvancing the group toward an end of conveying path 120.

In particular, as is illustrated in FIG. 1, supply conveyor 115 can be acontinuous belt conveyor that is driven by a supply conveyor drive motor117 over a set of supply conveyor pulleys 200 a and 200 b (see, e.g.,FIG. 2). In this configuration, supply conveyor 115 can advance bookletssuch as booklet 130 toward an end of conveying path 120, which can be incommunication with a feeder assembly, generally designated 135.Conveying path 120 can also include booklet side guides 125 for keepingthe group of booklets aligned as they are advanced. In addition,conveying path 120 can also include a paddle assembly 105 movable withsupply conveyor 115 for guiding the advancement of the booklets such asbooklet 130. Paddle assembly 105 can be angled relative to conveyingpath 120 for supporting the group of booklets at an angle (e.g., about a45° angle). Paddle assembly 105 can be guided along conveying path 120by paddle slide guides 110.

Referring now to FIG. 2, when a first booklet 130 in the group reachesan end of conveying path 120, one or more sensors 205 a and 205 b cansignal supply conveyor 115 to stop moving. In addition, an advancementbarrier can be provided for preventing the inadvertent advancement ofthe group. Examples of an advancement barrier can include a raised lip210 on the end of conveying path 120 (e.g., about ½ inch high) and/or aflexible hold-back 202 (e.g., a spring steel hold-back), both of whichare shown in FIG. 2.

Booklet feeder 100 can further include one or more booklet removers,such as grip removers 215 a and 215 b that can be contained withinfeeder assembly 135. These grip removers 215 a and 215 b can beconfigured for engaging booklets such as booklet 130 in a seriatimmanner in conveying path 120. Further, grip removers 215 a and 215 b canbe movable to remove an engaged booklet 130 from conveying path 120 andadvance the removed booklet 130 to an exit path, which is generallydesignated 230 in the Figures. Grip removers 215 a and 215 b can bemovable to lift the engaged booklet 130 past the advancement barrier(e.g., under flexible hold-back 202 and/or over raised lip 210). Forinstance, grip removers 215 a and 215 b can be configured to raisebooklet 130 away from the group of booklets and over raised lip 210(e.g., raise the bottom of booklet 130 about 1.25 inches)

In one aspect, grip removers 215 a and 215 b can comprise vacuum pickerassemblies, which can be carried on pivotable swing arms 220 a and 220b, respectively. Suction can be provided by a vacuum generator 224(e.g., a vacuum pump or pressurized air source), the operation of whichcan be regulated by a first vacuum control valve 222 and fed from an airpreparation system 144 (see FIG. 1). In such a system, grip removers 215a and 215 b are moved near booklet 130 and suction is created (i.e.,vacuum generator 224 is enabled). Booklet 130 is controllable engaged bygrip removers 215 a and 215 b such that booklet 130 can be moved withthe movement of grip removers 215 a and 215 b. When booklet 130 is movedto a desirable location, the suction is removed, and booklet 130 can bedisengaged from grip removers 215 a and 215 b.

Regardless of the specific design of grip removers 215 a and 215 b,however, grip removers 215 a and 215 b can be configured for engagingbooklets regardless of the booklet thicknesses. As a result, gripremovers 215 a and 215 b can advance booklets such as booklets 130having any of a variety of booklet thicknesses (e.g., number of pagesfrom 2 pages to about 100 pages or more) from conveying path 120 to exitpath 230. Further, because grip removers 215 a and 215 b need not bespecifically designed for a particular booklet thickness, booklet feeder100 can be used to advance groups of booklets having non-uniform bookletthicknesses (e.g., varying page counts and varying paper weights withinthe same stack) without requiring adjustments to booklet feeder 100. Forexample, as is shown in FIG. 3, a relatively thin booklet 130 a and arelatively thick booklet 130 b can be advanced in a continuous manner.Such flexibility can provide advantages over current booklet feeders,which, as noted above, are generally configured for a specific bookletthickness and would need to be adjusted before feeding a booklet havinga different thickness. This design thus allows for personalizationopportunities and possibly partnering with other print vendors.

As noted above, booklet 130 can then be moved toward exit path 230. Thismovement can be accomplished by pivoting lever arms 220 a and 220 b froma first position in which grip removers 215 a and 215 b are near the endof conveying path 120 to a second position above exit path 230.Specifically, lever arms 220 a and 220 b in the first position can beoriented at an angle relative to conveying path 120 to match the angleof booklet 130 (e.g., about 45 degrees). The pivoting of lever arms 220a and 220 b can be caused by the operation of a swing arm actuator 310(e.g., an air cylinder), which can be regulated by a second vacuumcontrol valve 223.

Exit path 230 can be an output conveyor, for instance having conveyorsections 232 a, 232 b, 242 a, and 242 b, for advancing the removedbooklet 130 away from grip removers 215 a and 215 b. In particular, exitpath 230 can comprise a first output conveyor stage composed of firstoutput conveyor sections 232 a and 232 b and a second output conveyorstage composed of second output conveyor sections 242 a and 242 b. Firstoutput conveyor sections 232 a and 232 b can be driven by a first drivemotor 234 (e.g., a stepper motor) connected through first drive pulleys236 a and 236 b. Second conveyor sections 242 a and 242 b can beindependently driven by a second drive motor 244 (e.g., another steppermotor) through second drive pulleys 246 a and 246 b. In thisarrangement, the first output conveyor stage can be adapted foradvancing the removed booklet 130 to the second output conveyor stage.In addition, the first output conveyor stage can further include firstbooklet pusher lugs 225 a and 226 a associated with first outputconveyor sections 232 a and 232 b, respectively, for assisting theadvancement of booklet 130 from the first output conveyor stage to thesecond output conveyor stage. In addition, first booklet pusher lugs 225a and 226 a can be complemented by additional booklet pusher lugsconnected to opposite ends of first output conveyor sections 232 a and232 b, respectively (see first booklet pusher lug 226 b complementary tofirst booklet pusher lug 226 a in FIG. 3). Similarly, the second outputconveyor stage can include second booklet pusher lugs 240 a and 241 aassociated with second output conveyor sections 242 a and 242 b,respectively, for assisting the advancement of booklet 130 out of feederassembly 135 for downstream processing. (Again, additional secondbooklet pusher lugs, such as second booklet pusher lug 241 b shown inFIG. 3 can also be provided.)

A controller, such as the computer controller generally designated 140in FIG. 1, can be provided to coordinate the advancement of booklet 130along conveying path 120, the engagement of booklet 130 by grip removers215 a and 215 b (e.g., vacuum picker assemblies), the movement of gripremovers 215 a and 215 b to move engaged booklet 130 from conveying path120 to exit path 230, and the advancement of booklet 130 along exit path230.

With a configuration such as is described above, booklet feeder 100 canoperate as shown in FIGS. 4 through 7. A group of booklets 405, whichcan have non-uniform booklet thicknesses, can be supported on conveyingpath 120. As noted above, group 405 can be supported on conveying path120 at an angle relative to conveying path 120 (e.g., about a 45°angle). Group 405 can be advanced along supply conveyor 115 toward gripremover 215 b, but advancement can be stopped when a first booklet 130in group 405 reaches an end of supply conveyor 115. It is noted thatalthough grip remover 215 a is not shown in this drawing, it is to beunderstood that both grip removers 215 a and 215 b can be positionedidentically to operate cooperatively together.

As is shown in FIG. 4, swing arm 220 b can be positioned such that gripremover 215 b is near a first booklet 130 of group 405. Specifically, asindicated above, swing arm 220 b can be positioned at an angle (e.g.,about 45 degrees) such that grip remover 215 b is angled complementarilyto the angle of booklet 130. Referring to FIG. 5, booklets 405 can thusbe engaged in a seriatim manner in conveying path 120 using grip remover215 b, for example by actuating the vacuum picker assembly serving asgrip remover 215 b. Referring to FIGS. 6 and 7, engaged booklet 130 canbe removed from conveying path 120 and advanced toward exit path 230. Asnoted above, booklet 130 can be advanced from conveying path 120 to exitpath 230 by the movement of grip remover 215 b. Specifically, swing arm220 b on which grip remover 215 b is carried can be pivoted from a firstposition (see, e.g., FIG. 5) in which grip remover 215 b is near the endof conveying path 120 to a second position (see, e.g., FIG. 7) aboveexit path 230. Furthermore, it is noted again that although grip remover215 a and swing arm 220 a are not shown, these elements can operate inthe same manner as is described with regard to grip remover 215 b andswing arm 220 b. Once booklet 130 is moved above exit path 230, booklet130 can be received on an output conveyor, such as a conveyor havingsections 232 a, 232 b, 242 a, and 242 b illustrated in the Figures (Onlysections 232 b and 242 b are shown in FIGS. 3-7). Specifically, movingbooklet 130 to the output conveyor can comprise moving booklet 130 to afirst output conveyor stage (first output conveyor sections 232 a and232 b), and advancing booklet 130 from the first output conveyor stageto a second output conveyor stage (second output conveyor sections 242 aand 242 b).

Accordingly, the methods and systems disclosed hereinabove provide thecapability to feed booklets with different page counts and differentpaper weights within the same stack. This capability creates a moreflexible system for document processing that can allow for greaterlevels of personalization and customization and can thus be incorporatedinto a wide variety of applications.

The present subject matter can be embodied in other forms withoutdeparture from the spirit and essential characteristics thereof. Theembodiments described therefore are to be considered in all respects asillustrative and not restrictive. Although the present subject matterhas been described in terms of certain preferred embodiments, otherembodiments that are apparent to those of ordinary skill in the art arealso within the scope of the present subject matter.

1. A booklet feeder for advancing booklets from a group of booklets, thebooklet feeder comprising: a conveying path for supporting a group ofbooklets with each booklet comprising a stack of bound sheet articles;and a grip remover configured for engaging booklets in a seriatim mannerin the conveying path, the grip remover being movable to remove anengaged booklet from the conveying path and advance the removed bookletto an exit path.
 2. The booklet feeder of claim 1, wherein the conveyingpath comprises a supply conveyor for advancing the group toward the gripremover.
 3. The booklet feeder of claim 2, wherein the supply conveyorcomprises a paddle assembly movable with the supply conveyor, the paddleassembly being angled relative to the conveying path for supporting thegroup of booklets at about an angle.
 4. The booklet feeder of claim 2,wherein the supply conveyor comprises an advancement barrier forstopping the advancement of the group when a first booklet in the groupreaches an end of the supply conveyor; and wherein the grip remover ismovable to lift the engaged booklet past the advancement barrier.
 5. Thebooklet feeder of claim 1, wherein the grip remover comprises at leastone vacuum picker assembly.
 6. The booklet feeder of claim 5, whereinthe vacuum picker assembly is carried on a pivotable swing arm.
 7. Thebooklet feeder of claim 1, wherein the grip remover is configured forengaging booklets of different booklet thicknesses.
 8. The bookletfeeder of claim 1, wherein the exit path comprises an output conveyorfor advancing the removed booklet away from the grip remover.
 9. Thebooklet feeder of claim 8, wherein the output conveyor comprises a firstoutput conveyor stage and a second output conveyor stage, the firstoutput conveyor stage being adapted for advancing the removed booklet tothe second output conveyor stage.
 10. The booklet feeder of claim 1,further comprising a controller connected to the grip remover forcontrolling the movement of an engaged booklet from the conveying pathto the exit path.
 11. A booklet feeder for advancing booklets from agroup of booklets, the booklet feeder comprising: a conveying path forsupporting a group of booklets having non-uniform booklet thicknesses,the conveying path comprising a supply conveyor for advancing the grouptoward an end of the conveying path; at least one vacuum picker assemblyconfigured for engaging booklets in a seriatim manner in the conveyingpath, the at least one vacuum picker assembly being movable to remove anengaged booklet from the conveying path and advance the removed bookletto an exit path; and a controller connected to the at least one vacuumpicker assembly for controlling the movement of an engaged booklet fromthe conveying path to the exit path.
 12. A method for advancing one ormore booklets, the method comprising: supporting one or more booklets ina conveying path; engaging one of the booklets in the conveying pathusing a grip remover; removing the engaged booklet from the conveyingpath; and advancing the removed booklet to an exit path.
 13. The methodof claim 12, comprising supporting a group of booklets havingnon-uniform booklet thicknesses in the conveying path.
 14. The method ofclaim 12, comprising supporting the group at an angle relative to theconveying path.
 15. The method of claim 123, comprising advancing thegroup along a supply conveyor toward the grip remover.
 16. The method ofclaim 15, wherein advancing the group along a supply conveyor comprisesstopping advancement when a first booklet in the group reaches an end ofthe supply conveyor.
 17. The method of claim 12, wherein engagingbooklets comprises actuating a vacuum picker assembly.
 18. The method ofclaim 17, wherein advancing the removed booklet to an exit pathcomprises pivoting a swing arm on which the vacuum picker assembly iscarried.
 19. The method of claim 12, wherein advancing the removedbooklet to an exit path comprises moving the booklet to an outputconveyor.
 20. The method of claim 19, wherein moving the booklet to anoutput conveyor comprises moving the booklet to a first output conveyorstage and advancing the booklet from the first output conveyor stage toa second output conveyor stage.